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Fiber matrix composite material made from recycled carpet

a fiber matrix and carpet technology, applied in the field of substantial thermoplastic composite materials, can solve the problems of increasing the cost of wood products, and the scarceness of wood products, and achieve the effects of high compressive strength, high flexibility, and easy bonding

Inactive Publication Date: 2005-10-20
INNOVATION INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0005] The composite material is resistant to moisture, solvents, degreasing agents, insects and rodents. The material possesses a smooth consistency with superior flexibility, surface durability, and high compressive strength. The composite can be sawed, screwed, nailed, drilled and machined using common tools. The material paint bonds easily with an aqueous or oil-based primer, and can be applied as a laminate, shaped or contoured, or heat formed. The high water resistance of the composite renders it ideal for outdoor applications, such as railroad ties, construction framing, agricultural buildings, wherein the material will be exposed to extremes of moisture and humidity. The properties of the composite material can also render it an excellent substitute for lumber in some applications. The composite has been found to be longer lasting than wood and wood products such as wood profiles, structural members, and sized lumber. Many wood products are slowly becoming scarce and more expensive as demand increases. The composite material can also be used as a superior, economical substitute for structural members such as wood and concrete railroad ties, since the composite is substantially more resistant to flexing and cracking problems commonly encountered with concrete, wooden members and other materials.

Problems solved by technology

Many wood products are slowly becoming scarce and more expensive as demand increases.

Method used

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Examples

Experimental program
Comparison scheme
Effect test

example 1

[0040] A composite material was extruded according to a method of the invention. The material was then tested according to standard procedures to quantify various physical properties relevant to its use in commercial applications.

[0041] A sample of carpeting comprised of polypropylene backing and nylon tufts was shredded into 1 inch (2.5 cm ±10%) chunks, such that the length of the individual carpet fibers were between ⅜ inch (0.95 cm) and 3 inches (7.6 cm) long. The carpet chunks were then introduced into an NRM extruder having a screw ratio of 30 to 1. The extruder was set at temperatures of 550 to 660° F. (290 to 350° C.). The barrel pressure of the NRM ranged from 600 psi (4 MPa) to 2100 psi (14.5 MPa). The composite material was extruded through a 54″ (7 cm) EDI die at a rate of 47 inches (120 cm) / minute, and at a temperature of between 510 to 560° F. (266 to 294° C.). The product was then sent through a three roll stacked chill roll system and formed into a 0.25 in×4 ft×8 ft ...

example 2

[0050] A composite material is extruded according to a method of the invention. A sample of carpeting comprised of polypropylene backing and nylon tufts is shredded into 1 inch (2.54 cm) chunks, such that the length of the individual carpet fibers were between ⅜ inch (0.95 cm) and 3 inches (7.6 cm) long. Virgin metallocene polypropylene polymer (MI 1.5 gm-10 min−1) is introduced into the extruder. The carpet chunks are then introduced into an NRM extruder having a screw ratio of 30 to 1. The extruder is set at temperatures of 550 to 660° F. (290 to 350° C.). The barrel pressure of the NRM ranges from 600 psi (4 MPa) to 2100 psi (14.5 MPa). The composite material is extruded through a 54″ (7 cm) EDI die at a rate of 47 inches (120 cm) / minute, and at a temperature of between 510 to 560° F. (266 to 294° C.). The product is then sent through a three roll stacked chill roll system and formed into a 0.25 in×4 ft×8 ft (0.64 cm×1.2 m×2.4 m) sheet. The sheet is then cut into samples that mea...

example 3

[0051] A composite material is extruded according to a method of the invention. A sample of carpeting comprised of polypropylene backing and nylon tufts is shredded into 1 inch (2.54 cm) chunks, such that the length of the individual carpet fibers were between ⅜ inch (0.95 cm) and 3 inches (7.6 cm) long. Virgin Kevlar reinforcing fiber (10 cm length and about 10 micron diameter) is introduced into the extruder and a weight ratio of about 1 part Kevlar fiber per 10 parts of carpet recycles to form a carpet chunk blend. The carpet chunk blend is then introduced into an NRM extruder having a screw ratio of 30 to 1. The extruder is set at temperatures of 550 to 660° F. (290 to 350° C.). The barrel pressure of the NRM ranges from 600 psi (4 MPa) to 2100 psi (14.5 MPa). The composite material is extruded through a 54″ (7 cm) EDI die at a rate of 47 inches (120 cm) / minute, and at a temperature of between 510 to 560° F. (266 to 294° C.). The product is then sent through a three roll stacked...

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Abstract

The invention relates to a composite structural material comprising a fiber dispersed in a fused matrix, wherein the fiber is derived from carpet, carpet recycle, carpet scrap, or mixtures thereof, and wherein the fused matrix comprises a thermoplastic comprising nylon, polyolefin, or mixtures thereof. The invention also relates to a method of manufacturing a rigid board composite structural material comprising the steps comminuting carpet to a predetermined particle size, adjusting the carpet feed stock to a form a balanced feed stock, introducing the feed stock into an extruder, and extruding the feed stock to form a structural composite comprising fiber dispersed in a fused matrix.

Description

FIELD OF THE INVENTION [0001] The invention relates to a substantially thermoplastic composite material. This material can be used in the fabrication of a structural member. The structural members formed from the composite material can be formed in a variety of products, for example, as a hollow profile, a rigid board, a wallboard, a rail tie, tile backer board, roofing materials such as shingles and a substitute for sized lumber. The composite of the invention is formed from virgin or recycled thermoplastic materials and can comprise carpeting material and optional added components and comprises carpet fiber dispersed in a fused thermoplastic matrix. The invention also relates to a process for forming the composite material of the invention. BACKGROUND OF THE INVENTION [0002] Composite materials find a wide variety of uses in industrial and residential applications. Composites are used in the form of rough-cut lumber, sheet components, panels, profiles including a hollow profile, a...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): B29B17/00B32B27/04D04H1/00D04H1/42
CPCB29B17/0042B29L2031/10B29L2031/724B29L2031/7322C08J2377/04C08J11/06C08J2323/02C08J2323/10D04H1/42D04H1/4274D04H1/4291D04H1/4334D04H1/43835Y10T428/249924Y02W30/62
Inventor PIKE, MARK
Owner INNOVATION INC
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